topic 20 and 21

how does epos link to stock management?

•make sure enough stock is maintained

•shopping patterns monitored to interprety customer demand

how does epos link to purchasing patterns?

•decline in sales can trigger manufactures to limit production

•data can determine when products should be launched

How does epos link to customer data?

•buying trends for focus marketing

•email reciepts

•customer details for marketing

What is one off production?

unique, individually designed products e.g. wedding dress

What are the advantages of one off production?

Produces a unique, high quality bespoke product

What are the disadvantages of one of production?

expensive as uses high quality materials, more skilled workers required, individual client consultation and design work, having to set up individual manufacturing processes, fewer economics of sale

What is batch production?

used when a greater number of products are required, is efficient and cost-effective using simultaneous manufacturing processes.

What sort of processes are used within batch production?

Jigs, injection moulding, CNC machines for a faster and more accurate production of parts

What are the advantages of batch production?

simple production line, low unit costs, levels of automation, flexibility to adjust the production line

what are the disadvantages of batch production?

requires workers with a level of skill, high set up costs of the machinery,

What is mass production?

produces a high volume of products quickly and consistently. uses the division of labour where workers carry out a single process in turn and shift work

what are the advantages of mass production?

High levels of automation, requires less skilled workers to run the machines, low unit cost,

what are the disadvantages of mass production?

high set up costs and investment capital, requires skilled workers to set up and programme the machines, expensive machinery, less flexibility for product diversity

What is line production?

linear nature of a production line

What is unit production systems (UPS)

•Mainly used in the textile industry
•efficient, organised, computer controlles overhead transporter system
•uses hanging carriers to convey garments between workstations

What are the advantages of UPS?

•Reduces handling operations
•optimises labour and equipment use
•improves quality

What is the purpose of quick response manufacturing?

•reduces lead times
•rapid completition of product design and developments is vital to minimise delays
•creativity, quality and customer needs are given high priority throughout the process

What is QRM?

use of mainly computer based technology to make low volume, customised products efficiently and competitivley

What is scale of production?

use of particular manufacturing methods to suit the anticipated volume of sales

What is vertical in-house production?

•the company owns its supply chain
•minimises the need for external suppliers
•factories needs facilities for manufacturing all componentsW

What are the advantages of vertical in-house production?

•reduced risk of component price increase
•less susceptible to suppliers going out of business
•protects a brand and improves security of intellectual property rights
•quality assurance easier to implimentW

What are the disadvantages of vertical in-house production?

•specialisation reduced
•increase in administration
•reduction of flexibility

How do we use computer systems to plan and control?

•used to organise complex manufacturing processes •spreadsheets to organise schedules

•barcodes for transfer of component and stock infomation by scanning which reduces waste and improves response to changes in demand

•integrated circuit in RFID tags improves retail security

What are examples of industrial manufacturing systems?

modular / cell
jit

What is modular/ cell-production ?

•manufacturing cells combine CNC machines into a group, the cell is programmed to carry out a sequence of operations
•avgs transport materials/ parts to and from buffer zones
•robots with 6-axis load and unload machinery
produces efficient and flexible manufacturing

What is JIT?

•the manufacture of products as needed in response to existing orders

What are the advantages of JIT?

•Less warehouses and storage needed
•waste reduction, no waste and less damaged stock
•money isnt tied up in inventrory

What are the disadvantages of JIT?

•could be delays with suppliers
•parts could arrive damaged or could be missing
•no bulk buy discount

What is Flexible manufacturing systems?

using cnc and robot based cells to carry out bespoke and batch production

What are the 2 main features of fms?

modular / cell production
single minute exchange dies

What are single minute exchange dies?

•changing dies/moulds in under 10 minutes
•uses quick release locking devices and multi-purpose interchangable elements
•minimum downtime to obtain maximum possible revenue from investments in machines

How are computer controlled systems used in production?

CAD, prototyping using 3D printers, CAM, qc checks

How are computer controlled systems used in distribution?

Distribution through optimum loading patterns for freight containers

How are computer controlled systems used in storage?

Automatic warehouse organisation with AVGs, forklifts and aisle stacking machines
electronic point of sales systems record sales of products and automate re-stocking

What are standadised components?

Parts which are made common, interchangable and standard such as bolts and light bulbs
can be rellied upon when

What are bought in components?

parts which are sourced from external components, these are standardised so will intergrate into manufactured products easily

Why do manufactures use bought in components?

High volume of that part is needed
components can be bought in bulk to reduce unit cost
availability of sub assemblies
no need for expensive and time consuming manufacturing facilities

What are sub-assemblies?

a self contained, seperately manufactured element incoroporated in a final product assembly

what are disadvantages of stockpiling goods?

Possibility of stock being damaged
Designs going out of fashion
Storage costs
Money tied up in stock

What are three modern manufacturing systems which improves companies ability with dealing with changing demand of the product?

JIT, QRM, FMS

What is CAD?

uses computers to develop 2d and 3d drawings and computer models with a range of file types which can transfere to cam equipmentQ

What are the advantages of cad?

•design and development process is faster and more accurate due to advantages of editing and developing files rather than drawing by hand
•CAD facillitates collabaritive work across different offices and countrues
•accurate files can be sent to CAM machines
•designs can be rendered and drawn to scale
•peform tests before producing the product

What are the disadvantages of cad?

•expensive software to set up
•requires specialist training
•software requires regular updates and requires ongoing technological support
•as online, work can be disrupted or lost due to technological issues, forgetting to save or viruses
•loss of skill as it reduces the need for hand drawings

What are simulations?

its a computer run through of a cam process which can be viewed by a designer who recieves updates on its success

What are examples of simulations?

Cutting path of a CNC laser

What are advantages of simulations?

•hilights problems with manufacture and shows if the production is to be as expected
•shows how long it takes for something to be machines
•facilitates nesting of products to reduce waste
•clashes with tooling beyond the x, y or z limits will be shown

What are CAM processes?

•CAD files are downloaded onto CNC machines for the cutting and shaping of materials
•machine generates a control programme facilitating settings such as feed rate to suit the material being machined
•seamless transgere of files from CAD to CAM can make one-off production viable

What is CAM?

Using computer controlled equipment to machine materials

What is CNC?

programme, converted from CAD files which uses special codes to control CAM equipment

Whar is a CNC laster cutter?

•lasers use a high-energy laser beam to cut/vaporise material
•compressed gas or air removes the waste material leaving a clean edge
•2d CAD files are converted into a CNC programme
•x and y axis, speed and power are programmed to cut and engrave materials

what is CNC routing?

•CNC routers use high-speed cutters to machine 2D CAD files in sheet material
•3d CAD files can also be used
•uses x,y and z axis and the workpiece is fixed to the bed

What are CNC milling machines?

•move the workpiece in the x, y and z axis
•more robust then routers and move slower so suitable for metal
•tools can be automatically selected
•machines are enclosed to improve safety
•coolent improves tool life and quality of finish by providing lubrication and reducing heat
•operate much quicker, accurately and with greater endurance then human workers, only stop for essential maintenance

What is CNC turning?

•cnc lathes machine metals nad plastics in bars to create pre-programmed x and y axis profiles
•automatically change tools
•often teamed with milling machines and the robot arms in FMS cells

What are CNC plotter cutters?

•used to cut out shapes in compliant materials such as self adhesive vinyl
•use x and y axis and uses 2D CAD files
•often used for graphic
•pull the sheet material in and out of the machine (y) and the cutter moves side to side (x)

What is virtual modelling?

•uses 3D CAD files to simulate aspects of the peformance of a product before its manufactured
•CAM process can be simulated to ensure error free machining

What are examples of virtual modelling?

Computational fluid dynamics

finite element analysis

what is an example of rapid prototyiping

FSD

What is computational fluid dynamics?

•3D cad simulation tool for fluid or gas flow in or around a product
•vehicle drag can be tested in a simulated wind tunnel
•test results can inform aerodynamic improvements
•designers save money which is usually used on physical testing

what is finite element analysis?

•analysis of stress in elements of a CAD design
•allows designers to simulate forces, vibration or shock on products or components
•weak points are identified using a colour coded scale
•money and time can be saved as designs can be optimised by modifying and re-testing

What are rapid prototyping processes?

•use of machines to produce realistic 3D models from CAD files
•models are usually made from polymers

What are the benefits of rapid prototyping?

•fast process as needs minimal human input

•doesnt require highly skilled workers

•modelling is no longer expensive or time consuming

What is stereolithographic modeling?

•UV lasers solidifies layers of photopolymers
•designs can be realistically sprayed and decorated for apprasial by designers and potential customers

What is FDM?

•3D printers use it to build 3d models from cad files

•uses thin extruded thermoplastic filament

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What is EPOS?

•computer based scanned barcode system to see when customers purchased goods

•stock levels and triggering of stock recorded

•establishes product life cycle

•customer email and loyalty card for marketing